Wall construction

ABSTRACT

A building wall is formed by erecting on a concrete footing, masonry panels of at least one story height having corner and intermediate panels formed with a groove in the upper, lower, and one lateral edge of each panel and having a cooperating tongue member formed on the other lateral edge of the panels forming a plurality of joints sealed at the edges with a mastic material, and filled with grouting material to secure the wall to the footing, and form an integral wall. The upper portion of the wall is locked together through the use of concrete bars secured in the upper grooves to vertically extending rods used to lift the panels, the grooves then being filled with concrete to bond the panels together.

United States Patent Cooper 1 1 Aug. 22, 1972 [54] WALL CONSTRUCTION [72] lnventor: Russell C. Cooper, Rt. 3, Box 217,

Rochester, Minn. 55901 [63] Continuation of Ser. No. 840,681, July 10,

1969, abandoned.

[52] US. Cl. ..52/270, 52/274, 52/286, 52/293, 52/300, 52/439 [51] Int. Cl. ..E04b l/04, E040 H10 [58] Field of Search ..52/270, 271, 272, 274, 258, 52/259, 275, 286, 284, 293, 295, 300, 436,

2,810,287 10/1957 Anderson ..52/432 2,835,126 5/1958 Paolella ..52/293 X 2,882,712 4/1959 Carlson ..52/258 X 3,172,377 3/1965 Dewar ..52/274 X 3,503,165 3/1970 l-lardt ..52/293 X Primary Examiner-Price C. Faw, Jr.

[57] ABSTRACT A building wall is formed by erecting on a concrete footing, masonry panels of at least one story height having corner and intermediate panels formed with a groove in the upper, lower, and one lateral edge of each panel and having a cooperating tongue member formed on the other lateral edge of the panels forming a plurality of joints sealed at the edges with a mastic material, and filled with grouting material to secure the wall to the footing, and form an integral wall. The upper portion of the wall is locked together through the use of concrete bars secured in the upper grooves to vertically extending rods used to lift the panels, the grooves then being filled with concrete to bond the panels together.

4 Claims, 7 Drawing Figures PATENTED M 2 2 I973 YINVENTOR. Russell 6. Cooper BY 3 ATTORNE s WALL CONSTRUCTION This is a continuation of my copending application Ser. No. 840,681, filed July 10, 1-969, and now abandoned.

This invention relates to-the construction field and more particularly to a structure and method of forming a building wall of at least a one story height.

The general practice of erecting walls and particularly for residential buildings has almost entirely centered around the use of concrete blocks. That is, the basement walls or walls which are used to support the upper structure of the house or other similar building is formed by rows of concrete blocks which are substantially 18 inches in length, and approximately inches high and 10 inches wide with void spaces formed in the center of the blocks. The blocks are laid in an overlapping manner on top of each other in rows to form the lower part of the building walls. The practice of using building blocks replaced the previous practice of generally pouring concrete into forms to produce a wall having reinforcing members and which generally has been recognized as being of superior strength. However, with the advent of increased labor costs in preparing the forms and the amount of time involved, the use of blocks has replaced the practice.

The present invention is directed to erecting a wall which is of at least one story height by the use of concrete panels which are formed substantially 8 feet in height, 4 feet in width, and approximately 10 inches in depth. The corner panels are substantially 2 feet wide on the outside surfaces and otherwise conform to the general configuration of the intermediate panels which are secured in between the comer panels. The panels are set in place and form an integral wall assembly when the joints and the groove which is at the bottom of the panels are poured with a grouting material to form a bond between the concrete footing and the wall panels. The upper part of the wall is bonded or strengthened through the use of a locking bar or concrete which is poured into a groove at the top of the block, the groove containing additional strengthening members.

It is therefore a general object of the present invention to provide a wall construction and the method for erecting the same from building panels of at least one story height.

It is yet another object of this invention to provide a building wall by bonding all of the building wall panels into a solid wall construction.

It is still a further object of this invention to provide a building wall which may be erected in a relatively short period of time by comparison to the present day methods of using building blocks.

It is still another object of this invention to provide a structure and method of securing at least single story height building panels in place on a concrete footing.

It is yet another object of this invention to provide a structure and method of securing the upper portion of wall panels of the invention in a bonded arrangement and provide a means of securing the building structural members at the top of the walls.

These and other objects of this invention will become apparent from a reading of the attached description together with the drawings, the figure descriptions which are as follows:

FIG. 1 is a perspective view of a wall erected according to the invention with one wall broken away exposing the footing and flooring;

FIG. 2 is a sectional plan view of a panel and footing on which it rests;

FIG. 3 is a broken elevational section showing a building panel in place;

FIG. 4 is a plan sectional view showing a typical joint formed by two panels;

FIG. 5 is a top plan view in section of a comer panel;

FIG. 6 is a sectional perspective view of the top portion of a panel with structural rods secured in the groove; and

FIG. 7 is a section of an upper panel showing a groove and rod arrangement in preparation for pouring concrete in the groove.

A building construction 10 is best shown in FIG. 1 in which a plurality of intermediate panels 1 l are secured between four comer panels 12, all of the intermediate panels being substantially alike and all of the corner panels being alike. Certain of the intermediate panels such as those designated 11a contain openings therein which accommodate windows. The openings are preformed with the panels when the concrete panels are fabricated. Panels 11 and 12 rest upon a concrete footing 13 and the lower surface of the area bounded by the walls just described is finished with a floor 14. Intermediate panels 11 have a groove 15 formed in the upper edge thereof and a groove 16 formed on one of the lateral edges and also includes another. groove 17 (FIG. 3) at the bottom of panel 11. The tongue 20 is secured on the other lateral edge of panel 11 which is designed to mate with a corresponding groove 16 in another panel 11. A pair of void spaces 21 and 22 are also formed in panel 11, the space being one which is tapered from a larger dimension in groove 15 to a smaller dimension near the bottom of the panel. A pair of rod hook members 23 and 24 are embedded in panel 11 near the tongue and groove 20 and 16 respectively and extend vertically within groove 15 to a height of at least the depth of channel 15. That is, rods 23 and 24 may extend above the upper edge of panels 1 1 and they are then cut at the appropriate place after the panel has been erected on the footing.

Panel 11, which is 4 feet wide, 8 feet high and 10 inches thick weighs approximately 3,000 pounds and thus special equipment is required for handling the panels which completely sets the panels apart from the common building blocks. The void areas 21 and 22 are approximately 13 inches long and 4 inches wide at the top having approximately a 1 inch taper through approximately 7% feet of the height of the panel. The comers of panel 11 have a chamfer 25 starting approximately one-quarter inch from each side of the corner. Groove 16 is tapered where the outer part or mouth of groove 16 is approximately 4 inches wide, the inner part of the groove is approximately 2% inches wide, the depths of the groove being approximately 2 inches. The mating tongue portion extends approximately 2 inches from the end of panel 11, is approximately 2% inches in width at its furthest extension and is approximately 3% inches wide where the tongue joins the face of the lateral edge. Reinforcing materials may also be used in panel 11 to provide additional strengthening of the panel if it is so desired.

Due to the dimensions just set forth, a joint 26 is formed between tongue 20 and groove 16 at the lateral edges of the panels, it being observed that a space of approximately one-fourth inch appears between the abutting members forming the joint. The joint is completed by applying a mastic material 27 that forms a liquid seal at both edges of joint 26. That is, the mastic material is applied to both the inner and outer faces of panels 1 1 and for that matter, comer panels 12 where intermediate panels 11 mate therewith. The joint is made solid by introducing a grouting material 30 in the space between the lateral edge faces of the panels and the mating tongue and grooves 20 and 16. Further explanation of how the grouting material is applied to the joint will be set forth later.

Comer panel 12 (FIG. 5) is very similar to intermediate panels 11, the outside dimensions of the corner panel being 2 feet on each side. The panel is of course inches thick and has an inner face of approximately 1 foot, 2 inches on each inner face side. A tongue a and a groove 16a are substantially the same dimensions as that just provided for intermediate panel 11 and a chamfer a is formed on each corner in the same manner as panel 11. A groove is formed at the top and bottom (not shown) of panel 12 in the same manner as grooves 15 and 17 of intermediate panel 11. The footing 13 is generally wider than panels 11 and 12 (See FIGS. 1 and 3).

As shown in FIGS. 2 and 3, a plurality of pins 31 and 32 are set in footing 13 at the time the footing is prepared. Pins 31 and 32 are located along the inner wall line and the panels 11 and 12 have their inner faces abutted against pins 31 and 32 so that the panels may be held in place before the flooring 14 is poured or set in place. Generally, earth 33 is moved against the outer wall of panels 11 and 12 to position and hold the panels in place and the locating pins 31 and 32 properly position panels 11 and 12 to form the wall. As will be explained later, the panels are secured to footing 13 by grouting materials and the floor 14 is poured so as to cover the upper edge of pins 31 and 32.

Groove 15 at the top of each of the panels is appropriately prepared in one of two ways to secure the upper portion of the panels. A locking bar 34 (FIG. 3) is formed of a concrete material and may be pre-cast with longitudinal reinforcing rods formed therein. Additionally, a vertically extending bolt or pin 35 is secured within locking bar 34 and extends upwardly to engage a sill or other building member and hold it in place. Locking bar 34 is slightly narrower than groove 15 and may also be secured in place by grouting material 30. A plate member 37 overlies each of the void areas 21 and 22 so that the material which is placed in groove 15 will not flow into the void areas. Any suitable material may be used to cover the opening or fit in the opening to prevent the flow of material.

In certain applications of the wall panels 1 1 and 12, it will be desirable to pour concrete into groove 15 to form a locking bar and this is preceded by welding at least a single rod 40 horizontally within groove 15, to vertically extending pins 23 and 24. If desirable another rod 41 may be welded to pins 23 and 24 to provide additional strength. A vertically extending bolt 42 is welded to rod 40 and extends upwardly to form a building structural member engaging pin such as bolt 35 (FIG. 3). Using the configuration found in FIG. 6, the hook portion of pin 23 would be cut off below or even with the top of groove 15 and if the locking bar arrangement such as found in FIG. 3 is used, pin 23 would be cut flush with the bottom of groove 15.

As explained previously, the time involved in erecting a wall of the type described herein is considerably less than that of erecting rows of building blocks and the end result is one of having a stronger wall than that using building blocks. In erecting the walls, footing 13 is first poured at the building site and pins such as pins 31 and 32 are located in the footing which described the outline of the inner wall surface. That is, pins 31 and 32 are used to locate the inner edge of the walls. Starting with a comer panel 12, intermediate panels 1 1 or 11a are set in place in the manner as described in FIG. 4 where there is approximately a /4 inch spacing or gap between the lateral edge faces and the tongue and groove arrangements. After the last panel is set in place, mastic material 27 is applied to the edges of the joint on the outside and inside surfaces of the wall. Thus, there then exists an open space in the tongue and groove arrangement which is in communication with lower groove 17 which extends around the footing beneath panels 11,11a, and 12. Upon mastic 27 being applied to the blocks as just described, grouting material 30 is poured into each of the vertical joints formed by tongue and grooves 20 and 16 respectively and the grouting is allowed to flow into groove 17 and thus bond panels to footing 13. When a locking bar is used, and if panels 11 and 12 have void spaces such as spaces 21 and 22 therein, a covering or closing material is inserted into the top of the void spaces and grouting is poured between groove 15 and locking bar member 34 to bond the upper part of the wall construction.

In the event it is desirable to pour concrete into groove 15 to form the locking bar, horizontal reinforcing rods are first welded to upright pins 23 and 24 and if the hook portion of pin 23 extends above the upper edge of panels 11 and 12, the pins are cut off. Additionally, bolts 42 are welded to the horizontal bars to provide adequate anchoring points for the sill to be attached thereto.

Thus, it will be seen that I have provided a wall construction and method of erecting the same which is far superior to the method and end product for using the conventional concrete blocks. By the use of this construction and method, a wall may be constructed in a matter of hours that took several days to construct using the well-known techniques of working with building blocks. While I have not particularly shown a panel with a doorway frame therein, it is contemplated that such a panel may be formed in much the same manner as panels 1 1a incorporate the openings for windows.

What is claimed is:

1. In a building wall construction including substantially homogenious load bearing concrete panels of at least single story height, the combination comprising:

a. a concrete footing conforming to the outline of the building wall to be constructed;

b. a plurality of concrete corner panels disposed on said footing at each of the comers of said building wall, each of said comer panels having substantially a uniform thickness and height, with a groove formed in the upper, lower and one lateral edge thereof and having a cooperating tongue member relationship, said combination forming an integral formed on the other lateral edge thereof; wall construction. c. a plurality of intermediate concrete panels each of 2. The building wall construction as set forth in claim which has substantially the same uniform height 1 including:

' g. structural rods extending within and along the lon gitudinal axis of said locking bar means; h. and anchor bolts vertically disposed and extending upwardly above said locking bar means. 3. The building wall construction as set forth in claim 10 1 including:

i. a plurality of locating pin means disposed in said and thickness as said plurality of corner panels 5 with a groove formed in the upper, lower and one lateral edge thereof and with a cooperating tongue member formed on the other lateral edge thereof, said plurality of intermediate panels being erected on said footing in spatially disposed tongue and groove confronting relationship forming vertical d. mastic material disposed in the outer edges of each of Said ve ti al j i t f i a to contain laterally at least on the inward side of the wall. grouting; 4. The structure of claim 1 having a locking bar e. grouting integrally disposed in said vertical joints f which Includes;

between said mastic material and at least said J- a p f y P cof'lcl'ete b laid In end lower grooves of said panels in communication abumngfelatloflshlp PP g f ith id f ti secured lIl locking relationship therewith by said f. the locking bar means disposed in said upper grouting dlsposed between Sald P! y Q grooves of said plurality of intermediate and iq q bars and 531d pp grooves In cememlcorner panels, said locking bar means traversing nous relatlonshlpsaid joints between said panels in cementitious joints extending substantially the thickness of said concrete panels between said plurality of comer and intermediate panels;

concrete footing and extending upwardly for engaging the inner faces of said plurality of corner and intermediate panels, said footing being wider than the wall to be erected thereon and extending 

1. In a building wall construction including substantially homogenious load bearing concrete panels of at least single story height, the combination comprising: a. a concrete footing conforming to the outline of the building wall to be constructed; b. a plurality of concrete corner panels disposed on said footing at each of the corners of said building wall, each of said corner panels having substantially a uniform thickness and height, with a groove formed in the upper, lower and one lateral edge thereof and having a cooperating tongue member formed on the other lateral edge thereof; c. a plurality of intermediate concrete panels each of which has substantially the same uniform height and thickness as said plurality of corner panels with a groove formed in the upper, lower and one lateral edge thereof and with a cooperating tongue member formed on the other lateral edge thereof, said plurality of intermediate panels being erected on said footing in spatially disposed tongue and groove confronting relationship forming vertical joints extending substantially the thickness of said concrete panels between said plurality of corner and intermediate panels; d. mastic material disposed in the outer edges of each of said vertical joints forming a seal to contain grouting; e. grouting integrally disposed in said vertical joints between said mastic material and at least said lower grooves of said panels in communication with said footing; f. and locking bar means disposed in said upper grooves of said plurality of intermediate and corner panels, said locking bar means traversing said joints between said panels in cementitious relationship, said combination forming an integral wall construction.
 2. The building wall construction as set forth in claim 1 including: g. structural rods extending within and along the longitudinal axis of said locking bar means; h. and anchor bolts vertically disposed and extending upwardly above said locking bar means.
 3. The building wall construction as set forth in claim 1 including: i. a plurality of locating pin means disposed in said concrete footing and extending upwardly for engaging the inner faces of said plurality of corner and intermediate panels, said footing being wider than the wall to be erected thereon and extending laterally at least on the inward side of the wall.
 4. The structure of claim 1 having a locking bar means which includes: j. a plurality of preformed concrete bars laid in end abutting relationship in said upper grooves and secured in locking relationship therewith by said grouting disposed between said plurality of preformed bars and said upper grooves in cementitious relationship. 